Experimental and Modeling Analysis of Micro-Milling of Hardened H13 Tool Steel

2011 ◽  
Author(s):  
Hongtao Ding ◽  
Ninggang Shen ◽  
Yung C. Shin
Keyword(s):  
Tool Wear ◽  
Size Effect ◽  
Strain Gradient ◽  
Chip Formation ◽  
Micro Milling ◽  
Fe Model ◽  
Tool Steels ◽  
Gradient Plasticity ◽  
H13 Tool Steel ◽  
Continuous Chip

This study is focused on experimental evaluation and numerical modeling of micro-milling of hardened H13 tool steels. Multiple tool wear tests are performed in a micro side cutting condition with 100 μm diameter endmills. The machined surface integrity, part dimension control, size effect and tool wear progression in micromachining of hardened tool steels are experimentally investigated. A strain gradient plasticity model is developed for micromachining of hardened H13 tool steel. Novel 2D FE models are developed in software ABAQUS to simulate the continuous chip formation with varying chip thickness in complete micro-milling cycles under two configurations: micro slotting and micro side cutting. The steady-state cutting temperature is investigated by a heat transfer analysis of multi micro-milling cycles. The FE model with the material strain gradient plasticity is validated by comparing the model predictions of the specific cutting forces with the measured data. The FE model results are discussed in chip formation, stress, temperature, and velocity fields to great details. It is shown that the developed FE model is capable of modeling a continuous chip formation in a complete micro-milling cycle, including the size effect. It is also shown that built-up edge in micromachining can be predicted with the FE model.

Experimental Evaluation and Modeling Analysis of Micromilling of Hardened H13 Tool Steels

2011 ◽  
Vol 133 (4) ◽  
Author(s):  
Hongtao Ding ◽  
Ninggang Shen ◽  
Yung C. Shin
Keyword(s):  
Tool Wear ◽  
Size Effect ◽  
Strain Gradient ◽  
Chip Formation ◽  
Experimental Evaluation ◽  
Strain Gradient Plasticity ◽  
Fe Model ◽  
Tool Steels ◽  
Gradient Plasticity ◽  
Continuous Chip

This study is focused on experimental evaluation and numerical modeling of micromilling of hardened H13 tool steels. Multiple tool wear tests are performed in a microside cutting condition with 100 μm diameter endmills. The machined surface integrity, part dimension control, size effect, and tool wear progression in micromachining of hardened tool steels are experimentally investigated. A strain gradient plasticity model is developed for micromachining of hardened H13 tool steel. Novel 2D finite element (FE) models are developed in software ABAQUS to simulate the continuous chip formation with varying chip thickness in complete micromilling cycles under two configurations: microslotting and microside cutting. The steady-state cutting temperature is investigated by a heat transfer analysis of multi micromilling cycles. The FE model with the material strain gradient plasticity is validated by comparing the model predictions of the specific cutting forces with the measured data. The FE model results are discussed in chip formation, stress, temperature, and velocity fields to great details. It is shown that the developed FE model is capable of modeling a continuous chip formation in a complete micromilling cycle, including the size effect. It is also shown that the built-up edge in micromachining can be predicted with the FE model.

Novel analysis for nanoindentation size effect using strain gradient plasticity

2005 ◽  
Vol 53 (10) ◽  
pp. 1135-1139 ◽  
Author(s):  
Hunkee Lee ◽  
Seonghyun Ko ◽  
Junsoo Han ◽  
Hyunchul Park ◽  
Woonbong Hwang
Keyword(s):  
Size Effect ◽  
Strain Gradient ◽  
Strain Gradient Plasticity ◽  
Gradient Plasticity

Numerical Studies on Size Effect Behaviors of Glassy Polymers Based on Strain Gradient Elastoviscoplastic Model

2018 ◽  
Vol 86 (2) ◽  
Author(s):  
Yujun Deng ◽  
Jin Wang ◽  
Peiyun Yi ◽  
Linfa Peng ◽  
Xinmin Lai ◽  
...  
Keyword(s):  
Finite Element ◽  
Size Effect ◽  
Strain Gradient ◽  
Simulation Models ◽  
Theoretical Models ◽  
Deformation Energy ◽  
Glassy Polymers ◽  
Traditional Theory ◽  
Fe Model ◽  
Processing Load

The improvement of the accuracy and efficiency of microforming process of polymers is of great significance to meet the miniaturization of polymeric components. When the nonuniform deformation is reduced to the microscopic scale, however, the mechanics of polymers shows a strong reinforcement behavior. Traditional theoretical models of polymers which have not considered material feature lengths are difficult to describe the size effect in micron scale, and the process simulation models based on the traditional theory could not provide effective and precise guidance for polymer microfabrication techniques. The work reported here proposed strategies to simulate size effect behaviors of glassy polymers in microforming process. First, the strain gradient elastoviscoplastic model was derived to describe the size affected behaviors of glassy polymers. Based on the proposed constitutive model, an eight-node finite element with the consideration of nodes' rotation was developed. Then, the proposed finite element method was verified by comparisons between experiments and simulations for both uniaxial compression and microbending. Finally, based on the FE model, under the consideration of the effect of rotation gradient, the strain distribution, the deformation energy, and the processing load were discussed. These strategies are immediately applicable to other wide-ranging classes of microforming process of glassy polymers, thereby foreshadowing their use in process optimizations of microfabrication of polymer components.

A Finite Element Study of Chip Formation Process in Orthogonal Machining

2011 ◽  
Vol 1 (4) ◽  
pp. 19-45 ◽  
Author(s):  
Amrita Priyadarshini ◽  
Surjya K. Pal ◽  
Arun K. Samantaray
Keyword(s):  
Finite Element ◽  
Chip Formation ◽  
Critical Role ◽  
Fe Model ◽  
Orthogonal Machining ◽  
Adiabatic Shearing ◽  
Segmented Chip ◽  
The Right ◽  
Distribution Of Stress ◽  
Continuous Chip

This paper examines the plane strain 2D Finite Element (FE) modeling of segmented, as well as continuous chip formation while machining AISI 4340 with a negative rake carbide tool. The main objective is to simulate both the continuous and segmented chips from the same FE model based on FE code ABAQUS/Explicit. Both the adiabatic and coupled temperature displacement analysis has been performed to simulate the right kind of chip formation. It is observed that adiabatic hypothesis plays a critical role in the simulation of segmented chip formation based on adiabatic shearing. The numerical results dealing with distribution of stress, strain and temperature for segmented and continuous chip formations were compared and found to vary considerably from each other. The simulation results were also compared with other published results; thus validating the developed model.

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